Various types of vacuum insulated refrigerator cabinets and doors have been developed. However, known methods of fabricating vacuum insulated structures may suffer from various drawbacks. Document US2013/0257257A1 discloses a vacuum insulated structure comprising first and second basins. A polymeric barrier films and a heat sealing layer are provided on the first and second basins. The barrier film is disposed upon the first and second basins by laminating the barrier film onto the first and second basins or by co-extruding the barrier film with the first and second basins or by coating the barrier film onto the material used for the first and second basins.

One aspect of the present disclosure is a method of fabricating a vacuum insulated refrigerator structure. The method includes injection molding a first layer of a first polymer material. A second layer of a second polymer material is injection molded over at least a portion of the first layer, and a third layer of a third polymer material is injection molded over at least a portion of the second layer to form a first component such as a liner or a wrapper. A second component is secured to the first panel component to form a vacuum cavity therebetween. The vacuum cavity is filled with a porous material, and the vacuum cavity is evacuated to form a vacuum. At least one of the first and third layers includes a structural reinforcement such as a rib or screw boss of increased thickness that is formed during the injection molding process.

These and other features, advantages, and objects of the present disclosure will be further understood and appreciated by those skilled in the art by reference to the following specification, claims, and appended drawings.

• FIG. 1 is an isometric view of a refrigerator;
• FIG. 2 is an exploded isometric view of a refrigerator cabinet;
• FIG. 3 is an exploded isometric view of a refrigerator door;
• FIG. 4 is an isometric view of a door liner showing the inner ride of the door liner;
• FIG. 5 is a cross sectional view of the door liner of FIG. 4 taken along the line V-V;
• FIG. 6 is a partially fragmentary isometric view showing an injection molded structural reinforcement feature;
• FIG. 7 is a partially schematic view of a mold utilized for a first injection;
• FIG. 8 is a partially schematic view of a mold utilized for a second injection;
• FIG. 9 is a partially schematic view of a mold utilized for a third injection; and
• FIG. 10 is a cross sectional view of a vacuum insulated refrigerator structure according to one aspect of the present invention.

For purposes of description herein, the terms "upper," "lower," "right," "left," "rear," "front," "vertical," "horizontal," and derivatives thereof shall relate to the disclosure as oriented in FIG. 1. However, it is to be understood that the disclosure may assume various alternative orientations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification, are simply exemplary embodiments of the concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the disclosures herein are not to be considered as limiting, unless the claims expressly state otherwise.

With reference to FIG. 1, a refrigerator 1 may include a vacuum insulated cabinet structure 2, and one or more doors 4 and 6 that are movably mounted to the cabinet 2. The cabinet 2 may include an insulated fresh food compartment 10 that is accessible by opening doors 4 and 6, and a frozen food compartment 12 that can be accessed by opening drawer 8. Refrigerator 1 may also include an ice/water dispenser 14 mounted to door 4. Refrigerator 1 includes a cooling system (not shown) that may be mounted in a machine space 16 (see also FIG. 2) located in a lower rear portion of the refrigerator 1. The cooling system may comprise a compressor, condenser, evaporator, and other related components. Alternatively, the cooling system may comprise a thermoelectric system that utilizes thermoelectric elements.

With further reference to FIG. 2, cabinet 2 may comprise an outer wrapper 18 and an inner liner 20 that fits within the wrapper 18 when assembled. A trim breaker 22 may be utilized to seal front edge 24 of wrapper 18 to front edge 26 of liner 20. The wrapper 18 and/or liner 20, and/or trim breaker 22 may comprise multi-layer polymer structures that are impervious to atmospheric gasses such as oxygen, nitrogen, carbon dioxide, water vapor, and/or other gasses. These multi-layer structures may be formed utilizing a multistep injection molding process discussed below. Alternatively, only one or two of the components 18, 20, and 22 may be fabricated utilizing a multistep injection process. For example, wrapper 18 could comprise formed sheet metal, and liner 20 and trim breaker 22 could comprise a multilayer polymer structure. Various features such as ribs or raised portions 28 may be formed in liner 20, wrapper 18, and/or trim breaker 22 during the injection molding process as described in more detail below. As discussed in more detail below, the liner 20 and exterior wrapper 18 form an interior space or cavity between liner 20 and wrapper 18 when assembled, and the interior cavity is filled with a porous material. The cavity is then evacuated to form a vacuum insulated structure.

With further reference to FIG. 3, the doors 4 and 6 and/or drawer 8 may include a liner 30 and exterior wrapper or panel 32. The door liner 30 and exterior panel 32 may comprise multi-layer polymer structures that are impervious to gasses. These structures may be fabricated according to a process discussed below. Liner 30 may comprise shelves 34, raised reinforcing features 36, or other such three dimensional features that are formed during an injection molding process.

With further reference to FIGS. 4 and 5, a liner 30A includes first, second, and third layers of polymer material 38, 40, and 42, respectively. The first layer 38 may form an interior side 44 of liner 30A. Layer 38 may include raised portions 46, grooves or lower portions such as linear channels 48, a perimeter channel 50, and reinforcing ribs 52 and 54 that extend across the grooves 48 and perimeter channel 50, respectively. As discussed below, an injection molding process according to the present disclosure provides for formation of complex three dimensional features such as raised portions 46, grooves and channels 48 and 50, respectively, and ribs 52 and 54, respectively.

In a liner or other component according to the present disclosure, the first layer 38 and third layer 42 may comprise a nylon thermoplastic material, and the second layer 40 may comprise a relatively thin layer of Ethylene Vinyl Alcohol (EVOH). According to another aspect of the present disclosure, a liner 30A or other component may include a first layer 38 and third layer 42 that comprise a High Impact Polystyrene (HIPS), and the second layer 40 may comprise a relatively thin layer of EVOH. In general, EVOH is a good barrier to oxygen, but it is not a particularly good barrier with respect to water vapor. Accordingly, one or both of the layers 38 and/or 42 may comprise a material that provides a water vapor barrier. For example, layer 38 and/or layer 42 could comprise barrier nylon or a liquid crystal polymer. Alternatively, a fourth layer (not shown) of material such as Tetrafluoroethylene (THV), polychlorotrifluoroethylene (PCTFE), Cyclic Olefin Copolymer (COC), Cyclic Olefin Polymer (COP) or high density polyethylene (HDPE) providing a water vapor barrier may be injection molded between layers 38 and 40 or between layers 40 and 42. In general, the materials utilized to form layers 38, 40, 42 and/or additional layers may be chosen to provide specific barrier properties with respect to oxygen transmission, water vapor transmission, structural properties, and cost considerations.

With further reference to FIG. 6, the component 10A may be molded to include additional structural features such as a screw boss 56 that receives a threaded insert 58. The ribs 52, 54 and/or screw boss 56 or other such features may be formed by injection molding at the time first and/or third layers 38 and 42 are being formed. It will be understood that a wide range of three dimensional features may be formed during the injection molding process whereby layer 38 and/or 42 have a non-uniform thickness.

With further reference to FIGS. 7-9, a molding tool 60 includes a lower mold part 64, and first, second, and third upper parts 62A, 62B, and 62C, respectively. During a first molding step (FIG. 7), molten polymer material is injected through ports 68A in mold part 62A as shown by the arrows "A." The molten material flows into a first mold cavity 66A defined by mold parts 62A and 64 to form a first layer 38 (FIG. 8). After the first polymer material is injected, additional polymer material is injected through ports 68B as shown by the arrows "B" (FIG. 8) to fill a second cavity 66B defined by mold tools 62B and 64 to form a second layer 40 (FIG. 9) that extends over at least a portion of first layer 38. With further reference to FIG. 9, a third polymer material is then injected through ports 68C of mold part 62C as shown by the arrows "C" to fill cavity 66C and form a third layer 42 (see also FIGS. 5 and 6). The mold part 62C may include one or more cavities or other features 70A-70D that form ribs 52, 54 and/or screw bosses 56 and/or other such 3D features whereby the component formed by the tooling/process of FIGS. 7-9 has a non-uniform thickness. The mold part 64 may also include one or more cavities or other such features that are similar to the features 70A-70D to thereby form three dimensional features in first layer 38.

With further reference to FIG. 10 a vacuum insulated refrigerator structure such as a cabinet 2, doors 4, 6, and/or drawer 8, and/or a trim breaker 22 may include an outer component such as wrapper 18 or exterior panel 32, and an interior liner 20 or 30. The components 18, 20, 30, and/or 32 may comprise three or more layers of polymer material 38, 40, and 42 that are configured to provide a barrier to gas as discussed above. During assembly, perimeter edge portions or flanges 72 and 74 of the wrapper 18 and liner 20 are sealed together to form an interior space 76. The interior space 76 is then filled with silica powder 78 or other suitable material, and a vacuum is formed in the interior space 76. The vacuum may be formed by placing the assembled structure in a vacuum chamber (not shown), and an access opening or port in wrapper 18 and/or liner 20 may then be closed and sealed to seal off interior space 76. The assembly is then removed from the vacuum chamber. Once the interior space 76 is sealed, the vacuum assembly forms a vacuum insulated refrigerator structure such as cabinet 2, doors 4, 6, drawer 8, or other such refrigerator structure. If the structure comprises a refrigerator cabinet 2, a trim breaker 22 may be utilized to seal edge 24 of wrapper 18 to edge 26 of liner 20 as discussed above in connection with FIG. 2. If the vacuum insulated refrigerator structure comprises a door, a resilient seal strip 80 or the like may be positioned adjacent edge portions 72 and 74 to thereby seal the door 4 or 6 (or drawer 8) when in a closed position.

It is to be understood that variations and modifications can be made on the aforementioned structure without departing from the concepts of the present disclosure, and further it is to be understood that such concepts are intended to be covered by the following claims unless these claims by their language expressly state otherwise.